WARNING WARNING WARNING
Contents
1. PLUG RECEPTACLE 808 M8 Oe O88 OO Oe oda dodo ONE dl ESTEE EEE 6 SOE OTE HEE d THEMES God dibi EE COREE electronic control circuits rere et eet eerie ete ee ft eit ieee ite toe tote ir er et ft titre ess lt ee ee ee xXx x ra CONNECTION DIAGRAM m FRS TO 115VAC FIELD DISCONNECT SWITCH SCHEMATIC DIAGRAM BLOWER OFF DELAY l BuU L2 EQUIPMENT MON HPS RED RED RED ILK GROUND m oja 90 o m Fun BRN RED LPs NOTE 8 2 gt Oem 120 H ORN FUSED OR CIRCUIT PL2 HSI Alm SEC GRN YEL GRY BREAKER DISCONNECT 1 ojm 150 BAN LGPS WHEN USED SWITCH WHEN REQ D t iz D Fimo sec yot YEL IHI LOR oj 180 GRN YEL pO ee i p E cx IDR m Hel l tO Flam gt sec GRN YEL rs Pa e ajeeb pa h adk i N nte BRN 2 amp 1 FUZL 6 K YEL 10 44 NOTES PC 1 1 IDM PL4 MODEL PLUG CHART pins wt MODEL MODEL r m PU QDEL MODEL PIN RESSANCE K Tr 70 2 1 4 2 3 T 050 057 24 91 D paf bal 3 51080 058 24 120 PB o I 3 SF080 059 24 150 tli 100 060 24 180 PPS 120 1 24 220 Bag PLI2 Puz s 2 u NOTE 7 ITL 2 PL FHE 4 1 2 m EAC EAC 1 EJ 2ZE 2 _ A C ORCF AIRFLOW SELECTION CHART BASED ON 350 CFM T2. u1 s e rpul INY 1100 12 147 ge did Bu 6Bes jq ssod 1010 jue Ul urep ayesuapuoo x DUMA A SS OX21 S UOAAS inss id PaJIMSIL JO An99J9Q Buiqn1 nss d p lonnsqo 10 p lo uuoosiq Alddns sre uolysnqwoo p sn 5407 J aunssaid 566 zaju Bulzis 1u A Jadolg 10 49940 1e u uBlu o aq IIIA ajoAo Bune u 1x u ay uoniuBi Jaye s lnuluu S uryym suado J Ael p HO Jamo q p l5 l s ayy 10 uo IM Jamojig ponad 1 mojq Buunp su do Q3N3dO3ti HO 3SO10 LON aid HOLIMS 34 5993 4 IWAH MOT NadO SI ASNA ADVLIOA AHVGNOOSS vz AINIS YOYMS 5 qn ainssaid p onnsqo HO 49949 N3dO LON GIG HOLIMS 5993 EZ A EA 566 Ayes 10 uado yon1s HO 49949 paea SI yne Inun unu 2 p SI se jym p A01d SI awe 4 IVN IS 4 14 TV NHONEV 22 A A SED O HOUS 10 104 u09 uo 566 p solo yon1iS 110 400 o s lnului G pem pue Jamod yo uni SVD Ly poo S sinou E Jaye 1 5 IIM Io uoO s ljo o Bulyeay aaisseoons OM Ul NO Pp8u n1 Sul q seye spuoo s OE uIUMNA le9 unuuuuoo 18M0
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5. jo Aue ye lpul nl A snonunuoo S USElI SZ po snlels J ul uol o l s y o Buninej p SI pue pld Bnid japow sl Buissiui 51 Ionuoo ay uo saul r s usej luo sz sntels J dNLIS HO NOI1O313S 13GON qITvANI Ge 18 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 58UVB CALL FOR FREE CATALOG 1 800 644 5544 Packaged Service Training Classroom Service Training A94328 Copyright 2006 Carrier Corp 7310 W Morris St Indianapolis IN 46231 Printed in U S A Edition Date 08 06 Catalog No 58UVB 1SM Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces New 19
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7. 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 wires All factory wires can be left connected but field thermo stat connections may need to be disconnected depending on their length and routing 4 Position control box transformer and door switch assem bly 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 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 ap propriate degreaser To remove wheel a Mark blower wheel location on shaft before disassembly to ensure
8. all power to the furnace DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch a clean unpainted metal surface of the fur nace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily dis charged 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 un grounded objects etc 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touch ing control or wires 5 Use this procedure for installed and uninstalled un grounded furnaces 6 Before removing a new control from its container dis charge your body s electrostatic charge to ground to pro tect 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 fur nace Put all used AND new controls into containers be fore 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 Cons
9. furnace 5 Furnaces are equipped with permanent washable filter s Clean filter by spraying cold tap water through filter in op posite direction of airflow 6 Rinse filter and let dry Oiling or coating filter is not rec ommended 7 Slide filter into furnace 58UVB 58UVB COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN INDUCER HOUSING MOLDED DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE 4 FIELD INSTALLED Z SSC FACTORY SUPPLIEDDRAINTUBE A COUPLING LEFT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE ini h BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY CAP PLUG CONDENSATE TRAP FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE COUPLING RIGHT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED 1 2 IN CPVC STREET ELBOWS 2 FOR LEFT DRAIN OPTION A06449 Fig 5 Factory Shipped Upflow Tube Configuration Shown with Blower Access Panel Removed 8 Recapture filter retaining 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 accumulated 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
10. if the limit or flame rollout switch is open longer than 3 minutes or 10 successive limit trips occurred during high heat Control will auto reset after 3 hours Refer to status code 33 14 IGNITION LOCKOUT Control will auto reset after 3 hours Refer to status code 34 15 BLOWER MOTOR LOCKOUT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being turned ON in two successive heating cycles Control will auto reset after 3 hours Refer to status code 41 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 24 VAC wiring 25 MODEL SELECTION OR SETUP ERROR Either indicates the model plug PL4 is missing or incorrect or setup switch SVV1 1 or SVV1 6 is positioned improperly If code flashes only 4 times on power up control is defaulting to model selection stored in memory Check the following Thermostat call with SW1 1 ON Thermostat call with SW1 6 ON SVV1 1 and SVV1 6 both ON together Two different fumace models twinned W
11. 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 f Remove blower wheel from housing g Clean wheel per instructions on degreaser cleaner Do not get degreaser in motor 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rota tion NOTE Be sure to attach ground wire and reconnect blower harness plugs to blower motor 10 Reinstall blower assembly in furnace 11 Reinstall condensate trap and tubing if previously re moved a Reinstall condensate trap in hole in blower shelf b Connect condensate trap drain tubes See Fig 5 or tubing diagram on main furnace door for proper tube location 1 Connect 1 tube blue or blue and white striped from collector box 2 Connect 1 tube violet or unmarked from inducer housing 3 Connect 1 tube relief port green or pink from collector box c Connect field drain to condensate trap NOTE Ensure tubes are not kinked or pinched as this will affect operation 12 Reinstall control box transformer and
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13. switch SW1 6 OFF and then back ON After component test is completed put setup switch SVV1 6 in the OFF position and reconnect the R thermostat lead 332712 101 REV C A06562 Fig 20 Service Label i Tum setup switch SW1 1 to OFF position NOTE The component test feature will not operate if the j Remove tape to release blower access panel door furnace control is receiving any thermostat signals or until all switch and replace blower access panel time delays have expired k Operate furnace through 1 heat cycle to check for a To initiate Component Test proceed with the proper operation and check LED status following 1 If furnace is operating properly and LEDs indicate 1 Leave 115 v power to furnace turned on proper operation replace main furnace door 2 Remove main furnace door 3 The control can also assist in troubleshooting by perform 3 Remove blower access panel ing a Component Test The Component Test will function 4 Turn setup switch SW1 6 to ON position ally operate all furnace components except the gas valve 14 5 Manually close blower access panel door switch Use a piece of tape to hold switch closed b When items 1 through 5 above have been completed the following will occur NOTE To repeat component test turn setup switch SW1 6 to OFF and then back to ON c After component test perform the following 1 Remove tape to release blower access panel doo
14. 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 may result in minor personal injury or product and property damage NOTE is used to 58UVB 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 A05069 Fig 1 Furnace in Upflow Orientation EFFICIENCY RATING CERTIFIED ama ISO 9001 2000 CERTIFIED REGISTERED 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 service personnel When working on heating equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply 4 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Be careful of sharp metal edges etc Use care and wear protective clothing gloves and safety glasses when removing parts Follow all safety codes including the National Fuel Gas Code NFGC NFPA 54 2002 AN
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16. 1 0 Amp PL4 4Circuit Model Plug Connector 5 2 Electronic Air Cleaner Connection Common PL7 4 Circuit Communication Connector FACTORY CONTROL 2 FRS Flame Rollout Switch Man Reset SPST N C PL9 2 Circuit OATConnector wene 24VAC NOTES 5 FSE Fla me Proving Sensor Electrode PLIO 2 Circ it Connector 55 lt FUSE 3 Amp Automotive Blade Type PL11 IDM Connector 12 Circuit FIELD CONTROL 1 If any of the original equipment wire is replaced use wire rated for 105 C s H Factory Installed PLI2 1 Circ lt Inductor Splice Connector 2 Use only copper wire between the disconnect switch and the furnace junction box JB gt GV Gas Valve PL13 16 Circuit ECM Blower Ctrl Connector WIRING 24VAC 3 This wire must be connected to furnace sheet metal for control to prove flame GVR Gas Valve Relay DPST N O PL14 5 Circult ECM Blower Power Connector CONDUCTORON 4 Symbols are electrical representation only bi d HPS High Heat Pressure Switch SPST N O SW1 1 Manual Switch Status Code Recall SPST N 0 5 Solid lines inside PCB are printed circuit board conductors and are not included in legend s i HPSR High Heat Pressure Switch Relay SPST N C SW1 2 Manual Switch Low Heat Only SPSTIN O CONTROL 6 Replace only with a 3 amp fuse 2 HSI Hot Surface Igniter 115VAC SW1 3 Manual Switch Low Heat Rise Adj SPST N O 7 Inductor is used with 3 4 hp and 1 hp ECM Blower mo
17. 58UVB Dedicated Upflow Variable Capacity Condensing Gas Furnace Turn to the Experts Service and Maintenance Instructions For Sizes 060 120 Series 100 NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS PAGE SAFETY CONSIDERATIONS 1 GENERAL m l zaye az eee 3 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 3 CARE AND MAINTENANCE 3 Cleaning and or Replacing Air Filter 3 Blower Motor and Wheel Maintenance 4 Cleaning Burners 5 Cleaning Heat Exchangers 6 Flushing Collector Box and Drainage System 7 Servicing Hot Surface Igniter Zi Electrical Controls and VViring 9 Checking Heat Tape Operation If Applicable 10 sanea an e 88a 10 WIRING DIAGRAMS 11 TROUBLESHOOTING 11 A WARNING ELECTRICAL SHOCK FIRE OR OPERATION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage 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 p
18. HEAT PRESSURE SWITCH IS CLOSED Check for Plugged condensate drain Low inlet gas pressure if LGPS used Water in vent piping possibly sagging pipe Improper pressure switch wiring Stuck open low heat pressure switch Disconnected or obstructed pressure tubing CONTROL CIRCUITRY LOCKOUT Auto reset after 1 hour lockout due to Flame sense circuit failure Gas valve relay stuck open 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 R thermostat lead Reset power and then put setup switch SVV1 6 in the ON position to start the component test sequence Once initiated the fumace control will tum the inducer ON The inducer motor will run for the entire test The hot surface igniter and blower motor will be tumed ON for 15 seconds each When the blower is tumed OFF the inducer will be tumed OFF When the component test is completed one or more of the following codes will flash CODE DESCRIPTION 41 Indicates the inducer and blower motor tested OK Visual check of hot surface igniter required 25 SETUP ERROR Same as code 25 above 41 BLOWER MOTOR FAULT Indicates blower motor failed test Check blower wiring and fumace control 42 INDUCER MOTOR FAULT Indicates inducer motor failed test Check inducer wiring and fumace control To repeat component test tum setup
19. ON 1 1 os 2 NgpR RSS Cee e om doma im SAC 2 8 s l Sale aie aie tie U R ze 7 i 2 Po 3 bso DEF 5252 700 875 10501 1225 1225 1225 2 6 Fut SECT SEC2 H 2 080 100 DEF 7002 875 1050 1225 1400 17501 1750 S oaae i i 8 120 DEF 700 8752 1050 1225 1400 1750 2100 FRS Ls NOTE 6 i PL7 1 Default A C airflow when A C switches are in OFF postion 2 Default cont fan airflow when CF switches are in OFF position 5 1 1 1 1 im l 51 t Q 1 F g m l CF LEDS H 2 lolo e e eje o g B i G Com WW Y Y2 R A mo w2 Yi DHUM 24V SAWS 3 AIC Air Conditioning Adjustable Airflow CFM ND inductor Note 7 ACR AirConditioning Relay SPST N O LED Light Emitting Diode for Status Codes JUNCTION 1 ACRDI Air Conditioning Relay Defeat l umper LGPS Low GasPressure Switch PST N O J 8 1 BWM Blovver Motor ECM LPS Low Heat Pressure Switch SPST N O TERM NAL 5 CF Continuous Fan Adjustable Airflow CFM 15 Limit Switch Auto Reset SPST N C ki H COMMR Communication Relay SPDT PCB Printed Circuit Board mm CONTROL TERMINAL 2 CPU Microprocessor Circuitry 12 Circuit Connector DHUM DHUM Connection 24VAC PL2 4 Circuit amp IDM Connector 1 H EAC 1 Electronic Air Cleaner Connection 4 Circult ECM BIWM Connector WIRING 115VAC 1 115VAC
20. S BR LEURS LA BOTTE DE TRANSITION ROSE COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN CAP DE TRANSITION VERTE 4 E CAPUCHON LA BOITE DE TRANSITION ROSE CAP fel COLLECTOR BOX TUBE GREEN INDUCER HOUSING MOLDED DRAIN TUBE LA BONE DE TRANSITION VERTE BEHIND COLLECTOR BOX DRAIN TUBE fa PLUG TUBE DE VIDANDAGE MOULE DE LA CAGE DE LINDUCTEUR COLLECTOR BOX DRAIN TUBE BLUE TUBE DE LABO TE DE TRANSITION BLEUE CONDENSATE TRAP PIEGE A CONDENSAT p FIELD INSTALLED FACTORY SUPPLIED FIELD INSTALLED DRAIN TUBE COUPLING 3 FACTORY SUPPLIED DRAIN LEFT DRAIN OPTION _ TUBE COUPLING CONNECTEUR DE DRAIN TRE RIGHT DRAIN OPTION INSTALL SUR LE CHANTIER JOINT DU TUBE DE VIDANDAGE DRAIN DE GAUCHE OPTIONNEL INSTALL SUR LE CHANTIER FOURNI PAR MANUFACTURIER VIDANDAGE DRO TE OPTIONNEL 58UVB FIELD INSTALLED FACTORY SUPPLIED DRAINTUBE TUBE DE VIDANDAGE INSTALLE SUR LE FIELD NSTALLED FACTORY SUPPLIED CHANTIER FOURNI PAR MANUPACTURIER 1 2 IN CPVC STREET ELBOWS 2 FOR LEFT DRAIN OPTION UN COUDE DE 1 2 EN CPVC FOURNI PAR LE MANUFACTURIER ET ETRE INSTALL SUR LE CHANTIER POUR L APPLICATION A GAUCHE 1 All tubing must be connected securely and routed to avoid kinks and traps 2 Pressure tubing must always slope away from pressure switch to collector box connection as shown NOTEZ BIEN 1 Tous les tubes de drainage doivent tre instal
21. SI Z223 1 2002 in the USA CSA B149 1 05 National Standard of Canada Natural Gas and Propane Installation Codes NSCNGPIC in Canada and the Installation 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 GENERAL This furnace must be installed as a direct vent 2 pipe or ventilated combustion air condensing gas furnace see installation instructions for details This furnace must be 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 See Fig 1 and 2 AIRFLOW lt gt UPFLOW A06340 Fig 2 Approved Orientation ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 4 CAUTION UNIT DAMAGE HAZARD Failure to follovv this caution may damage furnace components Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will prevent 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
22. access to screws attaching burner box to cell Failure to follow this warning could result in property panel damage personal injury or death 10 Remove screws attaching burner box to cell panel See Gas valve switch MUST be facing forward or tilted Fig 6 slightly NOTE Burner box cover manifold gas valve and burner assembly should be removed as 1 assembly 19 Replace burner box cover 11 Clean heat exchanger openings with a vacuum and a soft brush See Fig 8 NOTE After cleaning inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products 20 Turn on gas and electrical supplies to furnace 21 Check for gas leaks 4 WARNING FIRE OR EXPLOSION HAZARD 12 Reverse items 4 through 10 for reassembly PRIMARY HX INLET OPENINGS 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 commercially available soap solution made specifically for the detection of leaks to check all connections 22 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
23. ace 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 ohms 5 Remove igniter assembly 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 BURNER FLAME BURNER 7 MANIFOLD A89020 Fig 11 Burner Flame A93081 Fig 12 Gasket on Collector Box GN TER EXTENDED IGNITER BRACKET HANDLE BRACKET IGNITER BRACKET MOUNTING SCREW A05075 Fig 13 Igniter Bracket 4 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 burner box parts while removing or replacing it e If replacement is required re
24. 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 A96305 quality combustion air improper vent termination incorrect size Fig 8 Cleaning Inlet Openings of Primary or damaged manifold orifice s improper gas or a restricted heat Heat Exchangers 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 4 CAUTION UNIT MAY NOT OPERATE Failure to attach 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 A93087 was removed check for any damage If gasket is damaged in any Fig 9 Combustion Air Intake Housing way it must be repaired To repair remove damaged gasket Gasket Repair section apply sealant releasing agent such as PAM cooking spray or equivalent must not contain corn nor canola oil halogenated 6 Disconnect dra
25. arning could result in electrical shock personal injury or death Igniter wires must be securely placed in slot in manifold 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace component damage Label all wires prior to disconnection when servicing grommet or else they could become pinched or severed controls Wiring errors can cause improper and hazardous and electrically shorted operation 16 Reconnect wires to gas valve and igniter Refer to furnace Lo 3 Disconnect wires or connectors to flame rollout switch wiring diagram for proper wire location gas valve igniter and flame sensor 17 Reinstall burner box pressure tube to gas valve regulator fitting 4 Disconnect combustion air intake pipe from intake hous ing 18 Reinstall gas supply pipe to furnace gas control valve us 5 Remove the pressure switch tube from intake housing ing backup wrench on gas valve to prevent rotation and improper orientation 6 Remove screws attaching intake housing to burner box and rotate intake housing away from burner box for re NOTE Use propane gas resistant pipe dope to prevent gas leaks mo DO NOT use Teflon tape 7 Using backup wrench disconnect gas supply pipe from WAR N N G furnace gas control valve 8 Disconnect pressure tubing from gas valve FIRE EXPLOSION UNIT DAMAGE HAZARD 9 Remove 2 screws attaching top filler panel and rotate up wards to gain
26. close blower access panel door switch Use a piece of tape to hold switch closed h After status code 11 flashes for at least 2 times remove R W W1 and Y Y2 jumpers LLO ITT Io A06456 Fig 18 Inducer Housing Drain Tube A06457 Fig 19 Funnel in Drain Tube and Antifreeze Running Through Trap 13 58UVB SERVICE If status code recall is needed disconnect the R thermostat lead reset power and put setup switch SVV1 1 in the ON position To clear the status code history put setup switch SW1 1 in the ON position and jumper thermostat terminals R VV VVT and Y Y2 simultaneously until status code 11 is flashed LED CODE STATUS CONTINUOUS OFF Check for 115 VAC at L1 and L2 and 24 VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has 24 VAC power RAPID FLASHING Line voltage 115 VAC polarity is reversed EACH OF THE FOLLOWING STATUS CODES IS ATWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status codes are erased automatically after 72 hours or as specified above 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 VV VV1 closed or R VV VV1 opens during the blower on delay period 13 LIMIT CIRCUIT LOCKOUT Lockout occurs
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28. direction arrow the arrow must point toward the blower 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 filter 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 specified media 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 2 Remove main furnace door and blower access panel 3 Release filter retainer wire See Fig 3 or 4 WASHABLE FILTER FILTER SUPPORT FILTER RETAINER WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET A00232 Fig 3 Bottom Filter Arrangement VVASHABLE FILTER IN FURNACE x FILTER RETAINER A WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET A00233 Fig 4 Filter Installed for Side Inlet NOTE Filters shown in Fig 3 and 4 can be in furnace blower compartment or in filter cabinet but not in both 4 Slide filter out of
29. door switch assem bly on blower shelf 13 Reconnect wires Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 21 A WARNING ELECTRICAL SHOCK 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 furnace control No component operation can occur Caution must be taken when manually closing this switch for service purposes 14 Turn on electrical supply Manually close blower access panel door switch Use a piece of tape to hold switch closed Check for proper rotation and speed changes be tween heating and cooling by jumpering R to G and R to Y Y2 on furnace control thermostat terminals See Fig 15 15 If furnace is operating properly release blower access pan el door switch replace blower access panel and replace main furnace door Step 3 Cleaning Burners The following items should be performed by a qualified service technician If the burners develop an accumulation of light dirt or dust they may be cleaned by using the following procedure 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Remove burner box cover 4 Using backup wrench disconnect gas supply pipe from furnace gas control valve 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace component damage Label all wires prior t
30. ff electrical supply to furnace 2 Remove main furnace door 3 Disconnect upper inducer housing drain connection cap from inducer housing See Fig 18 4 Connect field supplied 1 2 in I D inducer housing tube to upper inducer housing drain connection 5 Insert funnel in tube and pour one quart of antifreeze pro pylene glycol RV swimming pool antifreeze or equiva lent into funnel tube until it is visible at point where con densate enters open drain See Fig 19 10 FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING 1 STAGE FIVE THERMOSTAT FIELD SUPPLIED WIRE TERMINALS FUSED DISCONNECT THREE WIRE HEATING 208 230 OR ONLY 191 460 1 THREE PHASE LK s l KA Le mum ml 17 208 230 oe o e tat fa sche 115 VOLT FIELD JUNCTION Bi e SUPPLIED BOX H i iL ri a a FUSED CONTROL DISCONNECT Box 2 24 VOLT TERMINAL NOTES 1 Connect Y Y2 terminal as shown for proper operation BLOCK 2 Some thermostats req
31. 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 unit wiring information A06522 Fig 14 Igniter NOTE If the polarity is not correct or 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 furnace control See Fig 16 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 The furnace control LED will flash status code 24 when fuse needs to be replaced With power to the unit disconnected check all electrical connections 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 and check 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 req
32. freeze coolant or equivalent automotive type 6 Replace drain connection cap and clamp to inducer hous ing 7 Replace main furnace door 8 Propylene glycol need not be removed before restarting furnace WIRING DIAGRAMS See Fig 15 16 and 21 for the Deluxe 4 Way Multipoise Furnace wiring diagrams TROUBLESHOOTING Use the troubleshooting guide the status code LED on the furnace control and the component test to isolate furnace operation problems A more detailed troubleshooting guide is available from your distributor For an explanation of status codes refer to service label located on back of main furnace door See Fig 20 The furnace control stores all status codes for a period of 72 hours regardless of 115 v or 24 v power interruption NOTE Removing blower access panel opens blower access panel door switch and terminates 115 v power to furnace control 12 Before removing blower access panel or turning off 115 v power look into blower access panel sight glass for current LED status 1 To retrieve status code proceed with the following NOTE NO thermostat signal may be present at furnace control and all blower time delay periods must be completed a Leave 115 v power to furnace turned on b Remove main furnace door c Look into blower access panel sight glass for current LED status code d Remove blower access panel e Turn setup switch SW1 1 to ON position See Fig 16 or 21 for loca
33. in tube from inducer housing See Fig hydrocarbons nor aromatic content to prevent inadequate seal 10 m from occurring to burner box and apply a small bead of G E NOTE Ensure the drain tube disconnected from the inducer HS RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant to housing is higher than the collector box opening or water will edge of combustion air intake housing See Fig 9 flow out of tube 13 Refer to furnace wiring diagram and reconnect wires to 7 Remove inducer housing assembly by removing 4 bolts flame rollout switch gas valve igniter and flame sensor attaching assembly to cell panel 14 Reconnect pressure switch tubes to gas valve and intake 8 Flush inside of collector box with water until discharge housing Refer to tube routing label on main furnace door from condensate trap is clean and runs freely for proper tube location See Fig 10 Be sure tubes are 9 Inspect inside area of collector box for any pieces of for not kinked eign materials and remove them if present 15 Turn on gas and electrical supplies to furnace 16 Check furnace operation through 2 complete heat operat A CAUTION ing cycles Look through sight glass in burner enclosure to check burners Burner flames should be clear blue almost UNIT DAMAGE HAZARD transparent See Fig 11 17 Check for gas leaks 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could Failure to follow this ca
34. iring diagram for model plug number and resistance values if code flashes continuously Board date code 4106 or later required to recognize plugs 057 061 HIGH HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED Indicates the high heat pressure switch input failed to close on a call for high heat or opened during high heat Control relay may be defective or gas valve is mis wired Refer to status code 32 LOW HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED Indicates the low heat pressure switch input failed to close on a call for low heat or opened during low heat If opens during 5 minutes after ignition the next heating cycle will be restricted to high heat Check for Proper vent sizing Plugged condensate drain Low inlet gas pressure if LGPS used Excessive wind Restricted combustion air supply Improper pressure switch wiring Water in vent piping possible sagging pipe Disconnected or obstructed pressure tubing Failed or Out of Calibration pressure switches LIMIT CIRCUIT FAULT Indicates the limit or flame rollout is open or the furnace is operating in high heat only mode due to 2 successive low heat limit trips 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 Imprope
35. l s professionellement pour emp cher tout obstruction a l vacuation de l eau de condensat 2 De pression et la boite de transition doivent install s a coulement descendant 332713 201 REV A Emplacement du tube quand application est Side Optional Pi ge a condensat sur c te gauche optionnel BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY REFERENCE DASSEMBLAGE DU TUBE DU CIRCUIT DES BRULEURS CAPUCHON 3 PLUG COLLECTOR BOX ma BOUCHON DRAIN TUBE BLUE TUBE DE LABOITE DE TRANSITION BLEUE CONDENSATE TRAP PIEGE A CONDENSAT INDUCER HOUSING DRAIN TUBE VIOLET TUBE DE VIDANDAGE DE LA CAGE DE L INDUCTEUR VIOLETTE A06460 Fig 10 Furnace Pressure and Drain Tubing Diagram 4 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 commercially available soap solution made specifically for the detection of leaks to check all connections 16 Replace main furnace door Step 6 Servicing Hot Surface Igniter 4 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 The igniter does NOT require annual inspection Check igniter resistance before removal 1 Turn off gas and electrical supplies to furn
36. o disconnection when servicing controls Wiring errors can cause improper and dangerous operation 5 Remove wires from gas valve Note location for reassemb ly 6 Remove burner box pressure tube from gas valve regulator fitting 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 1 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 MANIFOLD MOUNTING SCREWS GASKET MANIFOLD GAS VALVE REGULATOR FITTING GAS CONTROL VALVE A02312 Fig 6 Burner Box Assembly IGNITER WIRES MUST BE PLACED IN THIS SLOT A05074 Fig 7 Igniter VVire Placement 12 Remove burner assembly from burner box NOTE All 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 grom met dressing the wires to ensure there is no tension on the igniter itself See Fig 7 58UVB 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this w
37. place igniter on igniter bracket and then install assembly into burner box to avoid damage to the igniter 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 ig niter wires to ensure there is no tension on the igniter it self See Fig 7 4 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 8 Reinstall burner box cover 9 Turn on gas and electrical supplies to furnace 10 Verify igniter operation by initiating control board self test feature or by cycling thermostat 11 If furnace failes to ignite properly verify position of igni ter See Fig 14 by removing the burner box assembly ac cording to instructions in Step 4 After verifying and or adjusting the location re install the burner box assembly according to the instructions in Step 4 Repeat igniter op eration test in item 10 12 Replace main furnace door Step 7 Electrical Controls and Wiring 58UVB 4 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 unit Check accessories and cooling unit
38. r switch and turn setup switch SW1 6 to OFF position 1 Inducer motor operates at medium speed through step 3 then turns off 2 After waiting for 15 sec hot surface igniter is energized for 15 sec then de energized 2 Replace blower access panel 3 Operate furnace through 1 heat cycle to check for 3 Main blower motor operates at midrange airflow proper operation and check LED status for 15 sec then turns off 4 If furnace is operating properly and LEDs indicate 4 After component operation test is completed 1 or proper operation replace main furnace door more fault codes 11 25 41 or 42 will flash See service label on back of main furnace door or Fig 20 for explanation of codes TRAN Transformer 115VAC 24VAC
39. r or misaligned limit and or limit shield Defective switch or connections Improper low heat gas input adjustment Loose blower wheel Stuck high heat solenoid in gas valve Proper rear air baffle IGNITION PROVING FAULT Control will try three more times before a lockout 14 occurs If flame signal is lost during blower on delay period blower will come on for the selected blower off delay Check for Gas valve defective or turned OFF Defective Hot Surface Igniter Manual valve shut off Low inlet gas pressure Flame sensor must not be grounded Inadequate flame carryover or rough ignition Control ground continuity Green Yellow wire MUST be connected to furnace sheet metal Proper flame sense micro amps 5 micro amps DC min 4 0 6 0 nominal Oxide buildup on flame sensor clean with fine steel wool BLOWER MOTOR FAULT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within the prescribed time limits Thirty seconds after being turned ON or ten seconds during steady state operation INDUCER MOTOR FAULT Indicates the inducer has not started within 20 seconds after a call for heat the inducer motor RPM is outside its valid range of operation or the inducer RPM signal was lost for 5 seconds during operation Check for Proper vent sizing Restricted combustion air supply Failed inducer motor Improper motor wiring LOW HEAT PRESSURE SWITCH OPEN WHILE HIGH
40. ram and reconnect wires to in ducer motor and pressure switches or connectors Step 5 Flushing Collector Box and Drainage 12 Reconnect pressure tubes to pressure switches See dia System gram on main furnace door for proper location of tubes 1 Turn off gas and electrical supplies to furnace Be sure tubes are not kinked See Fig 10 2 Remove main furnace door 13 Turn on gas and electrical supplies to furnace 3 Disconnect inducer motor and pressure switch wires or 14 Check furnace operation through 2 complete heat operat connectors ing cycles Check area below inducer housing vent pipe and condensate trap to ensure no condensate leaks occur If leaks are found correct the problem 15 Check for gas leaks 4 Disconnect pressure switch tubes 5 Disconnect vent pipe from inducer housing outlet by loos ening coupling clamp on inducer outlet TUBE ROUTING CHEMINEMENT DU TUBE Pressure tube and drain tube routing MUST match the diagrams below L installation des tubes a pression et a condensat doivent correspondent au schema ci dessous Condensate Trap Factory Installed Tube location when used in UPFLOW application Condensate Trap on LEFT in Blower Shelf Le pi ge a condensat est install par le manufacturier dans le compartiment ASCENDANT du ventilateur Blower Access panel removed CE F REL eee Panneau D acces Au Br leur Enlev REFERENCE D ASSEMBLAGE DU TUBE COLLECTOR BOX TUBE PINK DU CIRCUIT DE
41. rior to disconnecting Reconnect wires correctly Verify proper operation after servicing 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 equipment 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 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could cause corrosion of heat exchanger fire personal injury or death 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 compounds 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 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 and CAUTION These words are used with the safety alert
42. tion f Manually close blower access panel door switch Use a piece of tape to hold switch closed 4 WARNING ELECTRICAL SHOCK UNIT OPERATE HAZARD Failure to follow this warning could result in electrical shock personal injury or death MAY NOT Blower access panel door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes g The AMBER LED will flash the status codes in the order of occurence Record status codes until status code 11 flashes 1 short and 1 long h After status code 11 flashes the status codes will repeat until setup switch SW1 1 is turned off 1 Remove tape to release blower access panel door switch and replace blower access panel j Operate furnace through 1 heat cycle to test for proper operation and check LED status k If furnace is operating properly and LEDs indicate proper operation replace main furnace door 2 Status codes are erased after 72 hours or they can be manually erased by performing the following procedure a Leave 115 v power to furnace turned on b Remove main furnace door c Look into blower access panel sight glass for current LED status code d Remove blower access panel e Turn setup switch SW1 1 to ON position See Fig 16 or 21 for location f Jumper thermostat terminals R W W1 and Y Y2 on furnace control g Manually
43. tors of HSR Hot Surface Igniter Relay SPST N O SW1 4 Manual Switch Comfort Efficiency Adjustment FIELD WIRING 8 Factory connected when GPS not used HUM 24VAC Humidifier Connection 0 5 Amp Max 5 5 9 Blower off delay gas heating selections are 90 120 150 180 seconds cooling or heat pump 1 HUMR Humidifier Relay SPST N O SW1 5 Manual Switch Cooling CFM Ton SPST N O REW TERMINAL 90 seconds or 5 seconds when dehumidify call is active o 2 IDM Inducer Draft Motor 2 Speed Shaded Pole 5 1 6 Manual Switch Component Test SPST N O EQUIPMENT 10 Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will oO IDR Inducer Motor Relay SPST N O SW1 7 8 Manual Switches Bower Off Delay SPSTIN O 7 auto reset after three hours r IH LOR inducer Motor Speed Change Relay SPDT SW4 1 Manual Switch Twinning Main OFF Sec ON GROUND 11 Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box K Blower Door Interlock Switch SPST N O SW4 2 amp 3 FOR FUTURE USE 12 Blower motor BLWM and Inducer motor IDM are locked rotor overload protected by redundant Fig 21 Wiring Diagram 15 A06459 06620 yelsouul u y eld i JO e soull v 9U O fEUlUu JEJSOUAU ul199uuoo O S S 15 e I elsui 42443 BOeUINY y UM lqnedu
44. uire a C terminal connection as shown FURNACE 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A95236 Fig 15 Field VViring COMMUNICATION CONTINUOUS FAN FUTURE CONNECTOR CF AIRFLOVV APPLICATIONS MODEL PLUG SETUP SVVITCHES CONNECTOR O SW1 SETUP SWITCHES AND PL4 al OAT 4 BLOWER OFF DELAY aw C8 Bl 10 YAS Hill ici AIR CONDITIONING ES a A C AIRFLOVV z S SETUP SWITCHES HUMIDIFIER TERMINAL 24 VAC a s Q 0 5 AMP MAX 2 HUM ACRDJ AIR Jol RELAY DISABLE Sixt E JUMPER 24 V THERMOSTAT lt o ACRDJ TERMINALS noT T EA sil 5 a FLASH UPGRADE x CONNECTOR 5 FACTORY C 2 a ONLY STATUS AND COMM gs ct 42 a LED LIGHTS 2 q H z 3 AMP FUSE 8602 See 5 2 a dada u 1 TRANSFORMER 24 VAC m P CONNECTIONS 2 ju F QOOUB b VS HSI HI LO 115 VAC L2 NEUTRAL EAC 1 TERMINAL CONNECTIONS 115 VAC 1 0 AMP MAX PL1 LOW VOLTAGE MAIN 115 VAC L1 LINE PL2 HOT SURFACE HARNESS CONNECTOR VOLTAGE CONNECTIONS IGNITER amp INDUCER MOTOR CONNECTOR A06494 Fig 16 Variable Capacity Furnace Control 11 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED N Z TX A93058 Fig 17 Freeze Protection 4 CAUTION UNIT DAMAGE HAZARD Failure of plastic components may occur Do not use ethylene glycol Prestone II anti
45. uired If this application is where heat tape has been applied check to ensure it will operate when low temperatures are present NOTE Heat tape when used should be wrapped around the condensate drain trap and drain line There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape 4 CAUTION UNIT AND PROPERTY DAMAGE Failure to follow this caution may result in furnace component failures or water property damage 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 CONDENSATE DRAIN PROTECTION section of Installation Start up and Operating Instructions See Fig 17 Step 9 Winterizing 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace component damage Freezing condensate left in the furnace may damage the furnace 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 damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on 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 o
46. ult your local dealer for maintenance and maintenance contract availability 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury 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 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 neces sary 4 Check for proper condensate drainage Clean as necessary 5 Check for blockages in combustion air and vent pipes annually 6 Check burners for cleanliness annually Step 1 Cleaning and or Replacing Air Filter The air filter arrangement may vary depending on the application or orientation 4 WARNING FIRE CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in a 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 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
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48. ution may result in furnace component damage DO NOT use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as cutting of 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 Never test for gas leaks with an open flame Use a torque commercially available soap solution made specifically for the detection of leaks to check all connections result in serious injury death or property damage 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 SECONDARY HEAT EXCHANGERS must not contain corn nor canola oil halogenated hydrocarbons MR Bria nor aromatic content to prevent inadequate seal from occurring NOTE The condensing side inside of the secondary heat to inducer housing See Fig 12 Apply a small bead of G E exchangers CANNOT be serviced or inspected A small number RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant to 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 18 Replace main furnace door groove in collector box 11 Refer to furnace wiring diag
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