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58UVBDedicated UpflowVariable---CapacityCondensing Gas Furnace

Service and Maintenance InstructionsFor Sizes 060--120, Series 100

NOTE: Read the entire instruction manual before starting theinstallation.

TABLE OF CONTENTSPAGE

SAFETY CONSIDERATIONS 1. . . . . . . . . . . . . . . . . . . . . . . .

GENERAL 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 7. . . . . . . . . . . . . . . . . . . . . . .

Electrical Controls and Wiring 9. . . . . . . . . . . . . . . . . . . . . .

Checking Heat Tape Operation (If Applicable) 10. . . . . . . .

Winterizing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAMS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SHOCK, FIRE, OR OPERATIONHAZARD

Failure to follow safety warnings exactly could result indangerous operation, serious injury, death, or propertydamage.

Improper servicing could result in dangerous operation,serious injury, death, or property damage.

-- Before servicing, disconnect all electrical power tofurnace.-- When servicing controls, label all wires prior todisconnecting. Reconnect wires correctly.-- Verify proper operation after servicing.

! WARNING

ELECTRICAL SHOCK, FIRE, OR EXPLOSIONHAZARD

Failure to follow this warning could result in possibledamage to this equipment, serious personal injury, ordeath.

The ability to properly perform maintenance on thisequipment requires certain expertise, mechanical skills,tools, and equipment. If you do not possess these, donot attempt to perform any maintenance on thisequipment other than those procedures recommended inthe User’s Manual.

! WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could cause corrosion ofheat exchanger, fire, personal injury, or death.

Never store anything on, near, or in contact with thefurnace, such as:1. Spray or aerosol cans, rags, brooms, dust mops,vacuum cleaners, or other cleaning tools.2. Soap powders, bleaches, waxes or other cleaningcompounds, plastic or plastic containers, gasoline,kerosene, cigarette lighter fluid, dry cleaning fluids, orother volatile fluids.3. Paint thinners and other painting compounds, paperbags, or other paper products.

! WARNING

SAFETY CONSIDERATIONSRecognize safety information. This is the safety--alert symbol

. When you see this symbol on the furnace and ininstructions or manuals, be alert to the potential for personalinjury.

Understand the signal words DANGER, WARNING, andCAUTION. These words are used with the safety--alert symbol.DANGER identifies the most serious hazards which will result insevere personal injury or death. WARNING signifies a hazardwhich could result in personal injury or death. CAUTION is usedto identify unsafe practices which may result in minor personalinjury or product and property damage. NOTE is used to

2

highlight suggestions which will result in enhanced installation,reliability, or operation.

Installing and servicing heating equipment can be hazardous dueto gas and electrical components. Only trained and qualifiedservice agency personnel should install, repair, or service heatingequipment.

A05069

Fig. 1 --- Furnace in Upflow Orientation

Untrained personnel can perform basic maintenance functionsdescribed in User’s Information Manual such as cleaning andreplacing air filters. All other operations must be performed bytrained service personnel. When working on heating equipment,observe precautions in the literature, on tags, and on labelsattached to or shipped with the unit and other safety precautionsthat may apply.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Be careful of sharp metal edges, etc. Use care and wearprotective clothing, gloves, and safety glasses whenremoving parts.

CAUTION!

Follow all safety codes including the National Fuel Gas Code(NFGC) NFPA 54--2002/ANSI Z223.1--2002 in the USA, CSAB149.1--05 National Standard of Canada, Natural Gas andPropane Installation Codes (NSCNGPIC) in Canada, and theInstallation Standards, Warm Air Heating and Air ConditioningSystems (NFPA 90B) ANSI/NFPA 90B. Wear safety glasses andwork gloves. Have a fire extinguisher available during start--upand adjustment procedures and service calls.

GENERALThis furnace must be installed as a direct vent (2--pipe) orventilated combustion air condensing gas furnace (see installationinstructions for details). This furnace must be installed in anupflow application. An upflow furnace application is where theblower is located below the combustion and controls section ofthe furnace, and conditioned air is discharged upward. (See Fig.1 and 2.)

UPFLOW

AIRFLOW

A06340

Fig. 2 --- Approved Orientation

ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnacecomponents.

Electrostatic discharge can affect electronic components.Take precautions during furnace installation and servicingto protect the furnace electronic control. Precautions willprevent electrostatic discharges from personnel and handtools which are held during the procedure. Theseprecautions will help to avoid exposing the control toelectrostatic discharge by putting the furnace, the control,and the person at the same electrostatic potential.

CAUTION!

1. Disconnect all power to the furnace. DO NOT TOUCHTHE CONTROL OR ANY WIRE CONNECTED TOTHE CONTROL PRIOR TO DISCHARGING YOURBODY’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 aperson’s hand during grounding will be satisfactorily dis-charged.

3. After touching the chassis, you may proceed to service thecontrol or connecting wires as long as you do nothing thatrecharges 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 withstatic electricity), firmly touch furnace again before touch-ing control or wires.

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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 beinstalled in a furnace, follow items 1 through 5 beforebringing 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 MAINTENANCEFor continuing high performance and to minimize possiblefurnace failure, it is essential that maintenance be performedannually. Consult your local dealer for maintenance andmaintenance contract availability.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personalinjury or death.

Turn off the gas and electrical supplies to the unit beforeperforming any maintenance or service. Follow theoperating instructions on the label attached to thefurnace.

! WARNING

The minimum maintenance that should be performed on thisequipment 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 forproper 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 pipesannually.

6. Check burners for cleanliness annually.

Step 1—Cleaning and/or Replacing Air FilterThe air filter arrangement may vary depending on the applicationor orientation.

FIRE, CARBON MONOXIDE AND POISONINGHAZARD

Failure to follow this warning could result in a fire,personal injury, or death.

Never operate unit without a filter or with the bloweraccess panel removed. Operating a unit without a filteror with the blower access door removed could causedamage to the furnace blower motor. Dust and lint oninternal parts of furnace can cause a loss of efficiency.

! WARNING

NOTE: If the filter has an airflow direction arrow, the arrowmust 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 byspraying cold tap water through filter in opposite direction

of airflow. Rinse filter and let dry. Oiling or coating of thefilter is not recommended.

5. If equipped with factory specified disposable media filter,replace only with a factory specified media filter of thesame 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:


2. Remove main furnace door and blower access panel.

3. Release filter retainer wire. (See Fig. 3 or 4.)

WASHABLEFILTER

FILTERSUPPORT

FILTERRETAINER

WASHABLE FILTER ORDISPOSABLE MEDIA FILTERIN FILTER CABINET

A00232

Fig. 3 --- Bottom Filter Arrangement

FILTERRETAINER

WASHABLEFILTER

IN FURNACE

WASHABLE FILTER ORDISPOSABLE MEDIAFILTER IN FILTER CABINET

A00233

Fig. 4 --- Filter Installed for Side Inlet

NOTE: Filters shown in Fig. 3 and 4 can be in furnace blowercompartment or in filter cabinet, but not in both.

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 op-posite direction of airflow.

6. Rinse filter and let dry. Oiling or coating filter is not rec-ommended.

7. Slide filter into furnace.

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COLLECTOR BOX TUBE(PINK)

COLLECTOR BOX DRAIN TUBE(BLUE)

INDUCER HOUSING (MOLDED) DRAIN TUBE(BEHIND COLLECTOR BOX DRAIN TUBE)

FIELD-INSTALLEDFACTORY-SUPPLIED DRAIN TUBECOUPLING (LEFT DRAIN OPTION)

FIELD-INSTALLED FACTORY-SUPPLIED DRAIN TUBE

FIELD-INSTALLEDFACTORY-SUPPLIED1/2-IN. CPVC STREET

ELBOWS (2) FOR LEFTDRAIN OPTION

FIELD-INSTALLEDFACTORY-SUPPLIED DRAIN

TUBE COUPLING (RIGHTDRAIN OPTION)

COLLECTOR BOX TUBE (GREEN)

CONDENSATE TRAP

CAP

BURNER ENCLOSURE PRESSUREREFERENCE TUBE ASSEMBLY

PLUG

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 WheelMaintenanceTo ensure long life, economy, and high efficiency, cleanaccumulated dirt and grease from blower wheel and motorannually.

The inducer and blower motors are pre--lubricated and require noadditional lubrication. These motors can be identified by theabsence of oil ports on each end of the motor.

The following items should be performed by a qualified servicetechnician.

Clean blower motor and wheel as follows:


2. Remove main furnace door and blower access panel.

3. Disconnect wiresAll factory wires can be left connected, but field thermo-stat connections may need to be disconnected dependingon 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 offurnace casing, proceed to item 6. Otherwise remove trapand tubing as described below (See Fig. 5.):

a. Disconnect field drain connection from condensatetrap.

b. Disconnect drain and relief port tubes from condensatetrap.

c. Remove condensate trap from blower shelf.

6. Remove screws securing blower assembly to blower shelfand slide blower assembly out of furnace. Detach groundwire and disconnect blower motor harness plugs fromblower motor.

NOTE: Blower wheel is fragile. Use care.

7. Clean blower wheel and motor by using a vacuum withsoft brush attachment. Be careful not to disturb balance

weights (clips) on blower wheel vanes. Do not bend wheelor blades as balance will be affected.

8. If greasy residue is present on blower wheel, removewheel from the blower housing and wash it with an ap-propriate degreaser. To remove wheel:

a. Mark blower wheel location on shaft beforedisassembly to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing soeach arm is positioned at the same hole location duringreassembly.

c. Mark blower wheel orientation and cutoff platelocation to ensure proper reassembly.

d. Remove screws securing cutoff plate and removecutoff plate from housing.

e. Remove bolts holding motor mounts to blowerhousing and slide motor and mounts out of housing.

f. Remove blower wheel from housing.

g. Clean wheel per instructions on degreaser cleaner. Donot get degreaser in motor.

9. Reassemble motor and blower wheel by reversing items8b through 8f. Ensure wheel is positioned for proper rota-tion.

NOTE: Be sure to attach ground wire and reconnect blowerharness 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 ortubing diagram on main furnace door for proper tubelocation.

(1.) Connect 1 tube (blue or blue and white striped)from collector box.

(2.) Connect 1 tube (violet or unmarked) from inducerhousing.

(3.) Connect 1 tube (relief port, green or pink) fromcollector box.

58UVB

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c. Connect field drain to condensate trap.

NOTE: Ensure tubes are not kinked or pinched, as this willaffect operation.

12. Reinstall control box, transformer, and door switch assem-bly on blower shelf.

13. Reconnect wires.Refer to furnace wiring diagram and connect thermostatleads if previously disconnected. (See Fig. 21.)


Failure to follow this warning could result in electricalshock, personal injury, or death.

Blower access panel door switch opens 115--v power tofurnace control. No component operation can occur.Caution must be taken when manually closing thisswitch for service purposes.

! WARNING

14. Turn on electrical supply. Manually close blower accesspanel door switch. Use a piece of tape to hold switchclosed. Check for proper rotation and speed changes be-tween heating and cooling by jumpering R to G and R toY/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 replacemain furnace door.

Step 3—Cleaning BurnersThe following items should be performed by a qualified servicetechnician. If the burners develop an accumulation of light dirt ordust, 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 fromfurnace gas control valve.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnacecomponent damage.

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and dangerousoperation.

CAUTION!

5. Remove wires from gas valve. Note location for reassemb-ly.

6. Remove burner box pressure tube from gas valve regulatorfitting.

7. Unplug igniter from harness.

8. Remove igniter leads from slot in manifold grommet.

9. Remove screws that secure manifold to burner box. (SeeFig. 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 tostrike the hot surface igniter.

MANIFOLDMOUNTINGSCREWS

MANIFOLD

GAS VALVEREGULATORFITTING

GASCONTROLVALVE

CELLPANEL

GASKET

A02312

Fig. 6 --- Burner Box Assembly

IGNIT ER WIRES MUST BE PLACED IN THIS SLOT

A05074

Fig. 7 --- Igniter Wire Placement

12. Remove burner assembly from burner box.

NOTE: All burners are attached to burner bracket and can beremoved as 1 assembly.

13. Clean burners with soft brush and vacuum.

14. Reinstall manifold, orifice, and gas valve assembly inburner box. Ensure manifold seal grommet is installedproperly 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 theigniter itself. (See Fig. 7.)

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Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severedand electrically shorted.

! WARNING

16. Reconnect wires to gas valve and igniter. Refer to furnacewiring diagram for proper wire location.

17. Reinstall burner box pressure tube to gas valve regulatorfitting.

18. Reinstall gas supply pipe to furnace gas control valve us-ing backup wrench on gas valve to prevent rotation andimproper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks.DO NOT use Teflon tape.

FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in propertydamage, personal injury, or death.

Gas valve switch MUST be facing forward or tiltedslightly.

! WARNING

19. Replace burner box cover.

20. Turn on gas and electrical supplies to furnace.

21. Check for gas leaks.


Failure to follow the safety warnings exactly couldresult in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections.

! WARNING

22. Replace main furnace door.

Step 4—Cleaning Heat ExchangersThe following items should be performed by a qualified servicetechnician.

PRIMARY HEAT EXCHANGERS

If the heat exchangers get an accumulation of light dirt or dust onthe inside, they may be cleaned by the following procedure:

NOTE: If the heat exchangers get a heavy accumulation of sootand carbon, both the primary and secondary heat exchangersshould be replaced rather than trying to clean them thoroughlydue to their intricate design. A build--up of soot and carbonindicates that a problem exists which needs to be corrected, suchas improper adjustment of manifold pressure, insufficient or poorquality combustion air, improper vent termination, incorrect sizeor damaged manifold orifice(s), improper gas, or a restricted heatexchanger (primary or secondary). Action must be taken tocorrect the problem.



UNIT DAMAGE HAZARD


Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and hazardousoperation.

CAUTION!

3. Disconnect wires or connectors to flame rollout switch,gas valve, igniter, and flame sensor.

4. Disconnect combustion--air intake pipe from intake hous-ing.

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 re-moval.

7. Using backup wrench, disconnect gas supply pipe fromfurnace gas control valve.

8. Disconnect pressure tubing from gas valve.

9. Remove 2 screws attaching top filler panel and rotate up-wards to gain access to screws attaching burner box to cellpanel.

10. Remove screws attaching burner box to cell panel. (SeeFig. 6.)

NOTE: Burner box, cover, manifold, gas valve, and burnerassembly should be removed as 1 assembly.

11. Clean heat exchanger openings with a vacuum and a softbrush. (See Fig. 8.)

NOTE: After cleaning, inspect the heat exchangers to ensurethey are free of all foreign objects that may restrict flow ofcombustion products.

12. Reverse items 4 through 10 for reassembly.

PRIMARY HXINLET OPENINGS

A96305

Fig. 8 --- Cleaning Inlet Openings of PrimaryHeat Exchangers

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UNIT MAY NOT OPERATE

Failure to attach ground wire to an adequate casing groundmay cause the furnace control to lock out.

The ground wire from the gas valve MUST be attached tothe burner box attachment screw.

CAUTION!

NOTE: Be sure burner box gasket is installed between burnerbox and cell panel. (See Fig. 6.) If gasket is damaged, replace it.

NOTE: Inspect combustion--air intake housing. If foamed gasketwas removed, check for any damage. If gasket is damaged in anyway, it must be repaired. To repair, remove damaged gasketsection, apply sealant releasing agent such as PAM cooking sprayor equivalent (must not contain corn nor canola oil, halogenatedhydrocarbons nor aromatic content, to prevent inadequate sealfrom occurring) to burner box and apply a small bead of G.E.RTV 162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant toedge of combustion--air intake housing. (See Fig. 9.)

13. Refer to furnace wiring diagram and reconnect wires toflame rollout switch, gas valve, igniter, and flame sensor.

14. Reconnect pressure switch tubes to gas valve and intakehousing. Refer to tube routing label on main furnace doorfor proper tube location. (See Fig. 10.) Be sure tubes arenot kinked.


16. Check furnace operation through 2 complete heat operat-ing cycles. Look through sight glass in burner enclosure tocheck burners. Burner flames should be clear blue, almosttransparent. (See Fig. 11.)





! WARNING


SECONDARY HEAT EXCHANGERS

NOTE: The condensing side (inside) of the secondary heatexchangers CANNOT be serviced or inspected. A small numberof bottom outlet openings can be inspected by removing theinducer assembly. See Flushing Collector Box and DrainageSystem section for details on removing inducer assembly.

Step 5—Flushing Collector Box and DrainageSystem



3. Disconnect inducer motor and pressure switch wires orconnectors.

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet by loos-ening coupling clamp on inducer outlet.

PAM

RTV

A93087

Fig. 9 --- Combustion--Air Intake HousingGasket Repair

6. Disconnect drain tube from inducer housing. (See Fig.10.)

NOTE: Ensure the drain tube disconnected from the inducerhousing is higher than the collector box opening or water willflow out of tube.

7. Remove inducer housing assembly by removing 4 boltsattaching assembly to cell panel.

8. Flush inside of collector box with water until dischargefrom condensate trap is clean and runs freely.

9. Inspect inside area of collector box for any pieces of for-eign materials and remove them if present.

UNIT DAMAGE HAZARD


DO NOT use wire brush or other sharp object to inspect ordislodge materials in secondary heat exchangers as cuttingof the secondary heat exchanger protective coating mayoccur. Flush with water only.

CAUTION!

10. Reassemble inducer assembly by reversing items 5--7.Tighten the vent coupling clamp screw(s) to 15 in.--lb oftorque.

NOTE: If seal between the inducer housing and the collectorbox is damaged in any way, it must be repaired. To repair, applysealant releasing agent such as PAM cooking spray or equivalent(must not contain corn nor canola oil, halogenated hydrocarbonsnor aromatic content, to prevent inadequate seal from occurring)to inducer housing. (See Fig. 12.) Apply a small bead of G.E.RTV 162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant togroove in collector box.

11. Refer to furnace wiring diagram and reconnect wires to in-ducer motor and pressure switches or connectors.

12. Reconnect pressure tubes to pressure switches. See dia-gram on main furnace door for proper location of tubes.Be sure tubes are not kinked. (See Fig. 10.)


14. Check furnace operation through 2 complete heat operat-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.


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A06460

Fig. 10 --- Furnace Pressure and Drain Tubing Diagram




! WARNING


Step 6—Servicing Hot Surface Igniter

BURN HAZARD

Failure to follow this caution may result in minor personalinjury.

Allow igniter to cool before removal. Normal operatingtemperatures exceed 2000_F.

CAUTION!

The igniter does NOT require annual inspection. Check igniterresistance before removal.



3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected bytemperature. Only check resistance when the igniter is atroom temperature.

a. Using an ohm meter, check resistance across bothigniter leads in connector.

b. Cold reading should be between 40 ohms and 70ohms.

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 screwsecuring the igniter bracket to the burner box bracket(See Fig. 13.) and carefully withdraw the igniter andbracket assembly through the front of the burner boxwithout striking the igniter on surrounding parts. Notethat the igniter bracket has a handle that extends to thefront of the burner box to aid in handling. (See Fig.13.)

d. Inspect igniter for signs of damage or failure.

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��BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 11 --- Burner Flame

RTV

PAM

A93081

Fig. 12 --- Gasket on Collector Box

BRACKET

IGNITER

9/16˝

11/16˝

EXTENDED IGNITERBRACKET HANDLE

IGNITER BRACKETMOUNTING SCREW

A05075

Fig. 13 --- Igniter Bracket

UNIT DAMAGE HAZARD

Failure to follow this caution may result in prematurefailure of the igniter.

The igniter is fragile. DO NOT allow it to hit burner boxparts while removing or replacing it.

CAUTION!

e. If replacement is required, replace igniter on igniterbracket and then install assembly into burner box toavoid damage to the igniter.

6. To replace igniter and bracket assembly, reverse items 5athrough 5d.

7. Reconnect igniter wire connection and insert the igniterwires 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.)



Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severedand electrically shorted.

! WARNING

8. Reinstall burner box cover.


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/oradjusting the location, re--install the burner box assemblyaccording to the instructions in Step 4. Repeat igniter op-eration test in item 10.


Step 7—Electrical Controls and Wiring

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Failure to follow this warning could result in personalinjury or death.

There may be more than 1 electrical supply to the unit.Check accessories and cooling unit for additionalelectrical supplies.

! WARNING

The electrical ground and polarity for 115--v wiring must bemaintained properly. Refer to Fig. 15 for field wiring informationand to Fig. 21 for unit wiring information.

A06522

Fig. 14 --- Igniter

NOTE: If the polarity is not correct or furnace is not properlygrounded, the STATUS LED on the furnace control will flashrapidly and prevent the furnace from operating. The controlsystem also requires an earth ground for proper operation of thefurnace control and flame sensor.

The 24--v circuit contains an automotive--type, 3--amp fuselocated on the furnace control. (See Fig. 16.) Any direct shorts ofthe 24--v wiring during installation, service, or maintenance willcause this fuse to blow. If fuse replacement is required, use ONLYa fuse of identical size. The furnace control LED will flash statuscode 24 when fuse needs to be replaced.

With power to the unit disconnected, check all electricalconnections for tightness. Tighten all screws on electricalconnections. If any smoky or burned connections are found,disassemble the connection, clean all parts, strip wire, andreassemble properly and securely.

Reconnect electrical supply to unit and observe unit through 1complete operating cycle and check for proper operation.

Step 8—Checking Heat Tape Operation(If Applicable)In applications where the ambient temperature around the furnaceis 32_F or lower, freeze protection measures are required. If thisapplication is where heat tape has been applied, check to ensure itwill operate when low temperatures are present.

NOTE: Heat tape, when used, should be wrapped around thecondensate drain trap and drain line. There is no need to use heattape within the furnace casing. Most heat tapes are temperatureactivated, and it is not practical to verify the actual heating of thetape.

UNIT AND PROPERTY DAMAGE

Failure to follow this caution may result in furnacecomponent failures or water property damage.

If this furnace is to be operated in an unconditioned spacewhere the ambient temperatures may be 32_F or lower,freeze protection measures must be taken. SeeCONDENSATE DRAIN PROTECTION section ofInstallation, Start--up, and Operating Instructions. (See Fig.17.)

CAUTION!

Step 9—Winterizing

UNIT DAMAGE HAZARD


Freezing condensate left in the furnace may damage thefurnace.

CAUTION!

Check the following:

1. Check for signs of physical damage to heat tape such asnicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damageor 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 astructure where the temperature will drop to 32_F or below,winterize as follows:



3. Disconnect upper inducer housing drain connection capfrom inducer housing. (See Fig. 18.)

4. Connect field--supplied 1/2--in. I.D. inducer housing tubeto 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.)

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115-VOLT FIELD-SUPPLIED

FUSEDDISCONNECT

JUNCTIONBOX

CONTROLBOX

24-VOLTTERMINALBLOCK

THREE-WIREHEATING-

ONLY

FIVEWIRE

NOTE 2

NOTE 1

1-STAGETHERMOSTATTERMINALS

FIELD-SUPPLIEDFUSED DISCONNECT

CONDENSINGUNIT

FURNACE

COM

R

W C Y R G

GND

GND

FIELD 24-VOLT WIRINGFIELD 115-, 208/230-, 460-VOLT WIRINGFACTORY 24-VOLT WIRINGFACTORY 115-VOLT WIRING

Connect Y/Y2-terminal as shown for proper operation.Some thermostats require a "C" terminal connection as shown.If any of the original wire, as supplied, must be replaced, usesame type or equivalent wire.

208/230- OR460-VOLTTHREEPHASE

208/230-VOLTSINGLEPHASE

WHT

BLK

WHT

BLK

W/W1

W2

Y/Y2

G

NOTES: 1.2.3.

A95236

Fig. 15 --- Field Wiring

FLASH UPGRADE

CONNECTOR (FACTORY

ONLY)

ACRDJ AIR CONDITIONING RELAY DISABLE

JUMPER

HUMIDIFIER TERMINAL (24-VAC

0.5 AMP MAX.

CONTINUOUS FAN (CF) AIRFLOW

SETUP SWITCHES

COMMUNICATION CONNECTOR

AIR CONDITIONING (A/C) AIRFLOW

SETUP SWITCHES

MODEL PLUG CONNECTOR

SW1 SETUP SWITCHES AND BLOWER OFF-

DELAY

STATUS AND COMM LED LIGHTS

3-AMP FUSE

TRANSFORMER 24-VAC CONNECTIONS

PL3 ECM BLOWERHARNESS

CONNECTOR

PL1 LOW VOLTAGE MAINHARNESS CONNECTOR

EAC-1 TERMINAL (115-VAC 1.0 AMP MAX.)

115-VAC (L1) LINE VOLTAGE CONNECTIONS

115-VAC (L2) NEUTRAL CONNECTIONS

PL2 HOT SURFACE IGNITER & INDUCER

MOTOR CONNECTOR

24-V THERMOSTAT TERMINALS

FUTURE APPLICATIONS

DA

TE C

OD

E X

XX

XN

A06494

Fig. 16 --- Variable Capacity Furnace Control

12

32°F MINIMUM INSTALLED�AMBIENT OR FREEZE�PROTECTION REQUIRED

A93058

Fig. 17 --- Freeze Protection

UNIT DAMAGE HAZARD

Failure of plastic components may occur.

Do not use ethylene glycol (Prestone II antifreeze/coolant orequivalent automotive type).

CAUTION!

6. Replace drain connection cap and clamp to inducer hous-ing.


8. Propylene glycol need not be removed before restartingfurnace.

WIRING DIAGRAMSSee Fig. 15, 16 and 21 for the Deluxe 4--Way Multipoise Furnacewiring diagrams.

TROUBLESHOOTINGUse the troubleshooting guide, the status code LED on thefurnace control and the component test to isolate furnaceoperation problems.

A more detailed troubleshooting guide is available from yourdistributor.

For an explanation of status codes, refer to service label locatedon back of main furnace door. (See Fig. 20.)

The furnace control stores all status codes for a period of 72hours, regardless of 115--v or 24--v power interruption.

NOTE: Removing blower access panel opens blower accesspanel door switch and terminates 115--v power to furnace control.

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 controland 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 currentLED status code.

d. Remove blower access panel.

e. Turn setup switch SW1--1 to ON position. (See Fig.16 or 21 for location.)

f. Manually close blower access panel door switch. Use apiece of tape to hold switch closed.

ELECTRICAL SHOCK, UNIT MAY NOTOPERATE HAZARD


Blower access panel door switch opens 115--v power tofurnace control. No component operation can occurunless switch is closed. Caution must be taken whenmanually closing this switch for service purposes.

! WARNING

g. The AMBER LED will flash the status codes in theorder of occurence. Record status codes until statuscode 11 flashes (1 short and 1 long).

h. After status code #11 flashes, the status codes willrepeat until setup switch SW1--1 is turned off.

i. Remove tape to release blower access panel doorswitch and replace blower access panel.

j. Operate furnace through 1 heat cycle to test for properoperation and check LED status.

k. If furnace is operating properly and LEDs indicateproper operation, replace main furnace door.

2. Status codes are erased after 72 hours or they can bemanually 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 currentLED 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 onfurnace control.

g. Manually close blower access panel door switch. Use apiece of tape to hold switch closed.

58UVB

58UVB

13

h. After status code 11 flashes for at least 2 times, removeR, W/W1, and Y/Y2 jumpers.

A06456

Fig. 18 --- Inducer Housing Drain TubeA06457

Fig. 19 --- Funnel in Drain Tube and AntifreezeRunning Through Trap

14

A06562

Fig. 20 --- Service Label

i. Turn setup switch SW1--1 to OFF position.

j. Remove tape to release blower access panel doorswitch and replace blower access panel.

k. Operate furnace through 1 heat cycle to check forproper operation and check LED status.

l. If furnace is operating properly and LEDs indicateproper operation, replace main furnace door.

3. The control can also assist in troubleshooting by perform-ing a Component Test. The Component Test will function-ally operate all furnace components, except the gas valve.

NOTE: The component test feature will not operate if thefurnace control is receiving any thermostat signals or until alltime delays have expired.

a. To initiate Component Test proceed with thefollowing:

(1.) Leave 115--v power to furnace turned on.

(2.) Remove main furnace door.

(3.) Remove blower access panel.

(4.) Turn setup switch SW1--6 to ON position.

58UVB

15

(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 beencompleted, the following will occur:

(1.) Inducer motor operates at medium speed throughstep (3), then turns off.

(2.) After waiting for 15 sec, hot surface igniter isenergized for 15 sec, then de--energized.

(3.) Main blower motor operates at midrange airflowfor 15 sec, then turns off.

(4.) After component operation test is completed, 1 ormore fault codes (11, 25, 41, or 42) will flash. Seeservice label on back of main furnace door or Fig.20 for explanation of codes.

NOTE: To repeat component test, turn setup switch SW1--6 toOFF and then back to ON.

c. After component test, perform the following:

(1.) Remove tape to release blower access panel doorswitch and turn setup switch SW1--6 to OFFposition.

(2.) Replace blower access panel.

(3.) Operate furnace through 1 heat cycle to check forproper operation and check LED status.

(4.) If furnace is operating properly and LEDs indicateproper operation, replace main furnace door.

LEGEND

JUNCTION

TERMINAL

CONTROL TERMINAL

FACTORY POWER

WIRING (115VAC)

FACTORY CONTROL

WIRING (24VAC)

FIELD CONTROL

WIRING (24VAC)

CONDUCTOR ON

CONTROL

FIELD WIRING

SCREW TERMINAL

EQUIPMENT

GROUND

PLUG RECEPTACLE

NOTES:

3327

10-1

01 R

EV. A1. If any of the original equipment wire is replaced use wire rated for 105°C.

2. Use only copper wire between the disconnect switch and the furnace junction box (JB).3. This wire must be connected to furnace sheet metal for control to prove flame.4. Symbols are electrical representation only.5. Solid lines inside PCB are printed circuit board conductors and are not included in legend.6. Replace only with a 3 amp fuse.7. Inductor is used with 3/4 hp and 1 hp ECM Blower motors.8. Factory connected when (LGPS) not used.9. Blower off-delay, gas heating selections are (90, 120, 150, 180) seconds, cooling or heat pump

90 seconds or 5 seconds when dehumidify call is active.10. Ignition lockout will occur after four consecutive unsuccessful trials for ignition. Control will

auto-reset after three hours.11. Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box.12. Blower motor (BLWM) and Inducer motor (IDM) are locked-rotor overload protected by redundant

electronic control circuits.

A/C Air Conditioning (Adjustable Airflow -CFM)ACR Air Conditioning Relay, SPST (N.O.)ACRDJ Air Conditioning Relay Defeat JumperBLWM Blower Motor (ECM)CF Continuous Fan (Adjustable Airflow -CFM)COMMR Communication Relay, SPDTCPU Microprocessor / CircuitryDHUM DHUM Connection (24VAC )EAC-1 Electronic Air Cleaner Connection

(115VAC 1.0 Amp Max.)EAC-2 Electronic Air Cleaner Connection (Common)FRS Flame Rollout Switch, Man. Reset, SPST(N.C.)FSE Flame-Proving Sensor ElectrodeFUSE Fuse, 3 Amp, Automotive Blade Type,

Factory InstalledGV Gas ValveGVR Gas Valve Relay, DPST (N.O.)HPS High-Heat Pressure Switch, SPST (N.O.)HPSR High-Heat Pressure Switch Relay, SPST (N.C.)HSI Hot Surface Igniter (115VAC)HSIR Hot Surface Igniter Relay, SPST (N.O.)HUM 24VAC Humidifier Connection (0.5 Amp Max.)HUMR Humidifier Relay, SPST (N.O.)IDM Inducer Draft Motor, 2-Speed, Shaded PoleIDR Inducer Motor Relay, SPST (N.O.)IHI/LOR Inducer Motor Speed Change Relay, SPDTILK Blower Door Interlock Switch, SPST (N.O.)

IND Inductor (Note #7)LED Light Emitting Diode for Status CodesLGPS Low Gas Pressure Switch, SPST (N.O.)LPS Low-Heat Pressure Switch, SPST (N.O.)LS Limit Switch, Auto-Reset, SPST (N.C.)PCB Printed Circuit BoardPL1 12-Circuit ConnectorPL2 4-Circuit HSI & IDM ConnectorPL3 4-Circuit ECM BLWM ConnectorPL4 4-Circuit Model Plug ConnectorPL7 4-Circuit Communication ConnectorPL9 2-Circuit OAT ConnectorPL10 2-Circuit HSI ConnectorPL11 IDM Connector (12-Circuit)PL12 1-Circuit Inductor Splice ConnectorPL13 16-Circuit ECM Blower Ctrl. ConnectorPL14 5-Circuit ECM Blower Power ConnectorSW1-1 Manual Switch, Status Code Recall, SPST (N.O.)SW1-2 Manual Switch, Low-Heat Only, SPST(N.O.)SW1-3 Manual Switch, Low-Heat Rise Adj. SPST (N.O.)SW1-4 Manual Switch, Comfort/Efficiency Adjustment,

SPST (N.O.)SW1-5 Manual Switch, Cooling CFM/Ton, SPST (N.O.)SW1-6 Manual Switch, Component Test, SPST (N.O.)SW1-7,8 Manual Switches, Blower Off-Delay, SPST(N.O.)SW4-1 Manual Switch, Twinning Main (OFF) / Sec. (ON)SW4-2&3 FOR FUTURE USETRAN Transformer, 115VAC / 24VAC

GV

M

C HI

NOTE #3

BLU

BRN

HPS

GRN/YEL

FRSLS

NOTE #8

GRY

RED RED RED

LPS

(WHEN USED)LGPSBRN

FSEWHT

PL31

4

HSI

L1

FUSED OR CIRCUITBREAKER DISCONNECTSWITCH (WHEN REQ'D)

NOTE #2

GND

NEUTRAL

FU2

BLK

ILKPL10

JB

1

2

BLK

WHT

PL1

TRAN

BLWM

L1

EAC

-1

PL12

INDNOTE #7PL12

4

HSI

PL2

VS

BLK

WHTWHT

BLU

SEC

-2

CODE

SEC

-1HUM

FUSE

3-A

MP

W/W1DHUM G24VomCW2 Y/Y2 RY1 STATUS

LEDS

COMM

ACRD

J

PL8

PL9

OAT

SW4

PL7

A B C D

CF

AC

SW1PL

4

GRN/YEL

1. Default A/C airflow when A/C switches are in OFF position2. Default cont. fan airflow when CF switches are in OFF position

A/C OR CF AIRFLOW SELECTION CHART BASED ON 350 CFM/TON

1HSI2

SCHEMATIC DIAGRAM

IDR

TO 115VAC FIELD-DISCONNECT SWITCH

ILKEQUIPMENT GROUND

12

3HSIR

IHI/LOR

PL2

L2

L2

FU1

NOTE #6

PL1-8

R

PL1-6

L2

PL10

4

CPU

NOTE #5 PCB

PL31 2 3 4

BLWM

PL13

101617

54

321

EAC-1PL14

PL12INDNOTE #7

PL12

L1

EAC EAC-2

TRAN

115VACL1 L2

SEC2SEC1

24VAC

PL1-12

HPSR

GV

LPS

NOTE #8

LGPS(WHEN USED)

HPS

HI

PL1-2

PL1-4

PL1-3

PL1-10

PL1-5

W/W1

CPU

GVR

DHUMW2

Y/Y2G

Y1

COM NOTE #3C

M

PL1-1 FSENOTE #5

ACRCOMMR

PCB

1

1

1

2 210017501400

122512251225

1225

1050

1050

875

875

700

700

525

1205T080,100

DEF.DEF.

DEF.0603.5T080

SIZEMODEL

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

ORN

BLK

GRN/YEL

516 1 710

BLUYELG

RNRED

PL13 PL14

BLK

YEL

CONNECTION DIAGRAM

BLK

WHT

YEL

14 3 2

BLUYELG

RNRED

SW1-7,8BLOWER OFF DELAY

SELECTION

90SEC120SEC150SEC180 SEC

OFF

OFF

OFF

OFF

7 87 8

7 87 8

11

2

1

1

AC

RDJ

PRINTED

CIRC

IUT BOA

RD

PRINTED

CIRC

IUT BOA

RD

HUMRHUM

RED

MODEL MODELSIZE PLUG

HK70EZ

PIN RESISTANCE K

1 - 4 2 - 3060

3.5T0805T-080

100

057058059060

24242424

91120150180

PL4 - MODEL PLUG CHART

120 061 24 220

2700 875 1050 1225 1400 11750 1750

IDM

GRN/YEL

BRN

ORNYEL

WHTBLK

BLK

WHT

FRS LS

IDM

PL11

PL1-9PL1-11PL1-7

L2

NOTE #11

NEUTRAL - L2

EAC

-2

WHTRED

42

101

126 4

210

1

126

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * *

* * *

* *

* ** * * * * * *

* * * *

* *

* * * * * * *

* * *

** * * * * * * *

* * * * * * * *

* * *

* * * * *

* * * * * * *

* * * * * * ** * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * *

* * *

* *

* ** * * * * * *

* * * *

* *

* * * * * * *

* * *

** * * * * * * *

* * * * * * * *

* * *

* * * * *

* * * * * *

* * * * * * ** * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

A06459

Fig. 21 --- Wiring Diagram58UVB

58UVB

16

Is A

MB

ER

LE

D s

tatu

s lig

ht b

linki

ng O

N/O

FF

slow

ly w

ith a

com

bin

atio

n o

f sh

ort

and

long fla

shes?

Is A

MB

ER

LE

D s

tatu

s lig

ht blin

king

rapid

ly w

ithout a p

ause

?

Is A

MB

ER

LE

D s

tatu

s lig

ht on?

Dete

rmin

e s

tatu

s co

de.

The s

tatu

s co

de is

a 2

digi

t num

ber w

ith th

e fir

st d

igit

dete

rmin

edby

the n

um

ber

of sh

ort

fla

shes

and the

seco

nd d

igit

by th

e n

um

ber

of l

ong fl

ash

es?

Go to s

ect

ion b

elo

w fo

r th

e s

tatu

s co

de

that w

as

flash

ed.

YE

S

NO

YE

S

To r

eca

ll pre

vious

statu

s co

des

dis

connect

the R

therm

ost

at co

nnect

ion, re

set pow

er,

and p

ut se

tup s

witc

h S

W1-1

in the O

Nposi

tion.

The A

MB

ER

LE

D w

ill fla

sh the

statu

s co

des

in the o

rder

of occ

urr

ence

.R

eco

rd s

tatu

s co

des

until

sta

tus

code #

11

flash

es

(1 s

hort

and 1

long fl

ash

). A

fter st

atu

sco

de #

11 fl

ash

es

the s

tatu

s co

des

will

repeat.

Sta

tus

codes

are

era

sed a

fter

72 h

ours

or

can b

e m

anually

era

sed b

y puttin

g s

etu

psw

itch S

W1-1

in the O

N p

osi

tion a

nd

jum

perin

g R

, W/W

1, a

nd Y

/Y2 s

imulta

neousl

yuntil

sta

tus

code #

11 is

fla

shed.

When d

one

put se

tup s

witc

h S

W1-1

in the O

FF

posi

tion.

Check

for

corr

ect

line v

olta

ge p

ola

rity

.If u

nits

are

tw

inned, ch

eck

for

pro

per

low

-volta

ge (

24V

) tr

ansf

orm

er

phasi

ng.

Was

there

a p

revi

ous

statu

s co

de o

ther

than #

11?

Is d

oor

switc

h c

lose

d?

Is there

115V

goin

g to s

witc

h?

Repla

ce d

oor

switc

h.

Repla

ce tra

nsf

orm

er.

Does

the c

ontr

ol r

esp

ond to W

/W1, W

2, Y

1,

Y/Y

2, and G

(24V

) therm

ost

at si

gnals

?

Repla

ce furn

ace

contr

ol.

NO

NO

NO

NO

Is 2

4V

pre

sent

at W

/W1, W

2, Y

1, Y

/Y2 o

r G

therm

ost

at

term

inals

on t

he f

urn

ace

contr

ol?

NO

YE

S

YE

S

Repla

ce furn

ace

contr

ol.

Is there

24V

at S

EC

-1 a

nd S

EC

-2?

Is there

115V

at L1 a

nd L

2?

YE

S

NO

YE

S

YE

S

NO

YE

S

NO

YE

S

Run s

yste

m thro

ugh a

low

-heat, h

igh-h

eat,

or

coolin

g c

ycle

to c

heck

opera

tion.

Sta

tus

codes

are

era

sed a

fter

72 h

ours

or

can b

em

anually

era

sed b

y puttin

g s

etu

p s

witc

hS

W1-1

in the O

N p

osi

tion a

nd ju

mpering R

,W

/W1, a

nd Y

/Y2 s

imulta

neousl

y until

sta

tus

code #

11 is

fla

shed.

YE

S

NO

Clo

se c

ircu

it bre

ake

r and g

o b

ack

to S

TAR

T.

Check

for

contin

uity

in w

ire f

rom

circu

itbre

ake

r to

furn

ace

.

Is c

ircu

it bre

ake

r cl

ose

d?

Clo

se d

oor

switc

h.

Check

room

therm

ost

at

or

inte

rconnect

ing c

able

.

NO

YE

S

YE

S

NO

The t

herm

ost

at

is n

ot

com

patib

le w

ith t

he

furn

ace

cont

rol.

Eith

er in

stal

l a b

alla

st re

sist

or,

connect

the C

om

24V

therm

ost

at te

rmin

al t

oth

e t

herm

ost

at,

or

repla

ce t

he t

herm

ost

at.

Does

the p

roble

m r

epeat

when u

sing

a ju

mper

wire?

Dis

connect

all

the ther

furn

ace

contr

ol.

STA

RT

TR

OU

BLE

SH

OO

TIN

G G

UID

E -

VA

RIA

BLE

SP

EE

D

A02350a

58UVB

17

11

NO

PR

EV

IOU

S C

OD

E –

Sta

tus

cod

es

are

era

sed a

fter

72 h

ours

or

can b

e m

anua

llyera

sed

by

puttin

g s

etu

p s

witc

h S

W1-1

inth

eO

N p

osi

tion

and

jum

pe

rin

g R

,W

/W1,

an

d Y

/Y2 s

imu

ltan

eo

usl

y u

ntil

sta

tus

code

#11 is

flash

ed. R

un s

yste

m thro

ugh a

low

-h

ea

t, h

igh

-he

at,

or

coo

ling

cycl

e t

och

eck

syst

em

.

12

BLO

WE

R O

N A

FT

ER

PO

WE

R U

P –

(115V

OR

24V

) – N

orm

al o

pera

tion.

Blo

wer

runs

for

90

seco

nds,

if u

nit

ispow

ere

d u

p d

uri

ng

a c

all

for

heat (R

-W

/W1

close

d)

or

wh

en

(R

-W/W

1 o

pens)

duri

ng

the b

low

er

on-d

ela

yperiod.

13

LIM

IT C

IRC

UIT

LO

CK

OU

T –

Lo

cko

ut

occ

urs

ifth

e li

mit

or

flam

e r

ollo

ut sw

itch is

op

en

lon

ge

rth

an 3

min

ute

s o

r 1

0su

ccess

ive li

mit

trip

s occ

urr

ed d

uring h

igh-

heat.

Contr

ol w

ill a

uto

-rese

t after

3 h

ours

.S

ee c

ode

33.

14

IGN

ITIO

N L

OC

KO

UT

– S

yste

mfa

iled

toig

nite

gas

and p

rove

fla

me

in 4

attem

pts

.C

ontr

ol w

ill a

uto

-rese

t after

3 h

ours

. S

ee

statu

s co

de

34.

21

GA

S H

EAT

ING

LO

CK

OU

T –

Turn

off

pow

er

and w

ait

5 m

inute

sto

retr

y. C

heck

for:

-S

tuck

clo

sed

gas

valv

e r

ela

y o

n c

on

trol.

-M

isw

ire

or

sho

rt t

og

as

valv

ew

ire.

22

AB

NO

RM

AL F

LA

ME

-PR

OV

ING

SIG

NA

LF

lam

e is

pro

ved w

hile

gas

valv

e is

de-

energ

ize

d.

Induce

r w

ill r

un u

ntil

fault

iscl

ea

red.

Ch

eck

for:

-S

tuck

op

en o

r le

aky

gas

valv

e.

23

PR

ES

SU

RE

SW

ITC

H D

ID N

OT

OP

EN

–C

heck

for:

-O

bst

ruct

ed p

ress

ure

tube.

-P

ress

ure

switc

h s

tuck

clo

sed.

24

SE

CO

ND

AR

Y V

OLT

AG

E F

US

EIS

OP

EN

Check

for:

-S

hort

circ

uit

inse

condary

volta

ge (

24V

)w

irin

g in

cludin

gth

erm

ost

at le

ads.

Dis

connect

therm

osta

tle

ads

tois

ola

tesh

ort

circu

it.

32

LO

W-H

EAT

PR

ES

SU

RE

SW

ITC

H D

IDN

OT

CLO

SE

OR

RE

OP

EN

ED

– If opens

duri

ng b

low

er

on-d

ela

y peri

od,bl

ow

er

will

com

e o

nfo

r th

ese

lect

ed b

low

er

off-d

ela

y.If o

pens

with

in 5

min

ute

s after

igniti

on

the

nex

t heatin

gcy

cle

will

be r

est

rict

ed

tohig

h-h

eat.

Che

ckfo

r:-

Pro

per

vent si

zing.

-Low

inle

t gas

pre

ssure

(if

LG

PS

use

d).

-R

est

rict

ed

co

mbu

stio

na

ir s

up

ply

.-

Dis

connect

ed o

r obst

ruct

ed p

ress

ure

tubin

g.

-D

efe

ctiv

e o

r m

isw

ired p

ress

ure

sw

itches

- E

xcess

ive

win

d. *

- P

lugged

condensa

tedra

in.

-W

ate

rin

vent pip

ing, poss

ible

sagg

ing

pipe

33

LIM

IT C

IRC

UIT

FA

ULT

– I

nd

ica

tes

the

limit

or

flam

e r

ollo

ut

switc

his

open o

r th

efu

rnac

eis

op

era

ting

inh

igh

-he

at

on

lym

ode d

ue to 2

succ

ess

ive lo

w-h

eat lim

ittr

ips.

Blo

wer

will

run fo

r 4 m

in. o

r until

open

switc

h r

em

ake

s w

hic

hev

er

is lo

nger.

Ifopen

longer

than 3

min

., c

ode c

hanges

to lo

ckou

t #13.

If o

pen le

ssth

an 3

min

.st

atu

s co

de

#3

3 c

on

tinu

es

tofla

shu

ntil

blow

er

shuts

off.

Fla

me r

ollo

utsw

itch

req

uires

ma

nu

al r

ese

t. C

he

ckfo

r:-

Pro

per

rear

air b

affle

.-

Loose

blo

wer

wheel.

-D

efe

ctiv

e s

witc

h o

rco

nnect

ions.

-Im

pro

per

low

-heat gas

input

adju

stm

ent.

-Im

pro

per

or

mis

alig

ned li

mit

and/o

r lim

itsh

ield

.-

Stu

ck h

igh-h

eatso

lenoid

in g

as

valv

e.

34

IGN

ITIO

N P

RO

VIN

G F

AIL

UR

E –

Iffla

me is

no

t se

nse

dd

uri

ng t

he

tria

l for

ign

itio

np

eri

od

,th

e c

ontr

ol w

illre

pe

at

the

ign

itio

nse

quence

3 m

ore

times

befo

re lo

ckout

#14

occ

urs

.If

flam

esi

gnal i

s lo

st d

uri

ng

the

blow

er

on-d

ela

y peri

od, bl

ow

er

will

com

e o

nfo

r th

e s

ele

cte

dbl

ow

er

off

-de

lay.

Ch

eck

the

follo

win

gite

ms

first

be

fore

pro

cee

din

gto

the n

ext st

ep.

-G

as

valv

e turn

ed

off.

- M

anual

shut-

off

valv

e.

-G

ree

n/Y

ello

w w

ire

MU

ST

be

con

nect

ed

tofu

rnac

e s

he

et

me

tal.

-F

lam

e s

enso

r m

ust

no

t b

e g

rou

nd

ed

.To

dete

rmin

e w

heth

er

the

pro

blem

is in

the

gas

valv

e, ig

nite

r, o

r fla

me

senso

rth

esy

stem

can

be o

pera

ted

in c

om

ponent te

stm

ode.

To

check

the ig

nite

r re

move

the R

the

rmos

tat

con

ne

ctio

nfr

om

th

e c

ont

rol,

rese

t pow

er,

and

putse

tup

switc

h S

W1-6

inth

e O

Nposi

tion to s

tart

the c

om

ponent te

st.

Does

the ig

nite

rglo

w o

range/w

hite

by

the

end o

fth

e 1

5se

cond w

arm

-up p

eri

od?

Un

plu

g ig

nite

r h

arn

ess

fro

mco

ntr

ol a

nd

repeat co

mponentte

st b

y tu

rnin

gse

tup

switc

h S

W1-6

OF

F a

nd then b

ack

ON

.C

heck

for

115V

betw

een p

in 3

and

NE

UT

RA

L-L

2 o

nth

e c

ontr

ol.

Was

115V

pre

sentfo

r th

e 1

5se

cond p

eri

od?

Ch

eck

co

nn

ect

ion

s a

nd

retr

y.If c

urr

ent is

near

typic

al v

alu

e(4

.0-6

.0 n

om

inal) a

nd b

urn

ers

will

not

stay

on, re

peatch

eck

in h

igh-h

eat.

If b

urn

ers

will

still

notst

ay o

n r

epla

ceco

ntr

ol.

If

bu

rne

rso

pe

rate

inh

igh

-he

at

the

nsw

itch

to

low

-h

ea

t, c

heck

ma

nifo

ldp

ress

ure

. I

f O

K,ch

eck

burn

er

carr

yove

r a

nd

fla

me

senso

rlo

catio

n.

Cle

an fla

me

senso

r w

ith fin

est

eel w

ool

and r

ech

eck

curr

ent.

Nom

inalcu

rrent is

4.0

to 6

.0 m

icro

am

ps.

Iscu

rre

nt

ne

ar

typ

ica

l valu

e?

Re

pla

ce e

lect

rod

e.

Will

main

burn

ers

ignite

and s

tay

on?

Repla

ce furn

ace

contr

ol.

NO

YE

S

YE

S

YE

S

NO

NO

15

BLO

WE

R M

OT

OR

LO

CK

OU

T –

Indic

ate

sth

ebl

ow

er

faile

dto

reach

250 R

PM

or

the

blow

er

faile

d to

com

munic

ate

with

in 3

0se

conds

after

bein

g turn

ed

ON

in tw

osu

ccess

ive h

eatin

gcy

cles.

Contr

ol w

illauto

-rese

t after

3 h

ours

. S

ee c

ode

41.

45 C

ON

TR

OL

CIR

CU

ITR

YLO

CK

OU

T A

uto

-rese

tafter

1 h

our

lock

out due

to:

-F

lam

eci

rcu

itfa

ilure

.-

Ga

s va

lve

re

lay

stuck

open.

- S

oft

wa

rech

eck

err

or.

Rese

t pow

er

tocl

ear

lock

ou

t. R

ep

lace

co

ntr

ol

if co

de

repeats

.

Repla

ce furn

ace

contr

ol.

Ch

eck

for

contin

uity

in t

he

ha

rne

ssa

nd

ign

iter.

Re

pla

ced

efe

ctiv

e c

om

po

ne

nt.

Reco

nnect

the R

therm

ost

at le

ad

and

set

therm

ost

at

to c

all

for

heat. C

onnect

voltm

ete

r acr

oss

gas

valv

e c

onnect

ions.

Does

gas

valv

e r

ece

ive 2

4V

?

Do

es

gas

valv

e o

pe

n a

nd

allo

w g

as

toflo

w?

Do the m

ain

burn

ers

ignite

?

Do the m

ain

burn

ers

stay

on?

Allo

w b

low

er

toco

me o

n a

nd

repeat te

stto

check

for

inte

rmitt

ent opera

tion.

Check

that all

gas

valv

es

are

turn

ed

on

. R

ep

lace

valv

e.

Check

connect

ions.

IfO

K,

repla

ce c

ontr

ol.

Check

for:

- I

nadequa

tefla

me

carr

yove

ror

rough ig

niti

on.

-Low

inle

t gas

pre

ssure

.-

Pro

pe

rfir

ing

rate

.

Repeatca

llfo

r h

eat and c

heck

flam

ese

nso

rcu

rrent during tri

alf

or

igniti

on

pe

rio

d.

Isth

e D

Cm

icro

am

ps

be

low

0.5

?

YE

S

NO

43

LO

W-H

EAT

PR

ES

SU

RE

SW

ITC

H O

PE

NW

HIL

E H

IGH

-HE

AT

PR

ES

SU

RE

SW

ITC

H IS

CLO

SE

D -

Check

for:

-Low

-he

at

pre

ssu

re s

witc

h s

tuck

op

en.

-D

isco

nnect

ed o

r obst

ruct

ed p

ress

ure

tubin

g.

-Im

pro

per

pre

ssure

switc

h w

irin

g.

-Low

inle

t gas

pre

ssure

(if

LG

PS

use

d).

-P

lugged

condensa

tedra

in.

-W

ate

rin

vent pip

ing, poss

ible

saggin

gpip

e.

YE

S

YE

S

YE

S

YE

S

NO

NO

NO

NO

Fix

ed.

NO

*Se

t u

p s

witc

h S

W1

-3 t

o b

e O

N if

pro

ble

m p

ers

ists

.

A05076

58UVB

18

25IN

VALI

D M

OD

EL

SE

LEC

TIO

N O

RS

ET

UP

ER

RO

R –

If s

tatu

s co

de 2

5 on

lyfla

shes

4 ti

mes

on

pow

er-u

p th

e co

ntro

lis

mis

sing

its

mod

el p

lug

PL4

and

isde

faul

ting

to th

e m

odel

sel

ectio

n st

ored

in m

emor

y. I

f sta

tus

code

25

flash

esco

ntin

uous

ly it

cou

ld in

dica

te a

ny o

f the

follo

win

g:-

Mod

el p

lug

PL4

is m

issi

ng a

nd th

ere

is n

o va

lid m

odel

sto

red

in p

erm

anen

tm

emor

y. T

his

will

hap

pen

if yo

u fo

rget

to in

stal

l the

mod

el p

lug

PL4

on

ase

rvic

e re

plac

emen

t con

trol

.-

The

rmos

tat c

all w

ith S

W1-

1 O

N.

-T

herm

osta

t cal

l with

SW

1-6

ON

.-

SW

1-1

and

SW

1-6

both

ON

.-

Two

diffe

rent

furn

ace

mod

els

twin

ned.

31H

IGH

-HE

AT P

RE

SS

UR

E S

WIT

CH

OR

RE

LAY

DID

NO

T C

LOS

E O

RR

EO

PE

NE

D -

Che

ck fo

r:-

Con

trol

rel

ay m

ay b

e de

fect

ive.

-G

as v

alve

is m

isw

ired.

-S

ee s

tatu

s co

de 3

2.

41B

LOW

ER

MO

TOR

FA

ULT

– In

dica

tes

the

blow

er fa

iled

to r

each

250

RP

M o

r th

ebl

ower

faile

d to

com

mun

icat

e w

ithin

the

pres

crib

ed ti

me

limits

. T

hirt

y se

cond

saf

ter

bein

g tu

rned

ON

or

ten

seco

nds

durin

g st

eady

-sta

te o

pera

tion.

Tur

n po

wer

off a

nd c

heck

the

follo

win

g ite

ms

first

befo

re p

roce

edin

g to

the

next

ste

p.-

Rub

bing

blo

wer

whe

el.

-Lo

ose

blow

er w

heel

.-

Wiri

ng fr

om fu

rnac

e co

ntro

l to

blow

erm

otor

.R

emov

e th

e R

ther

mos

tat c

onne

ctio

nfro

m th

e fu

rnac

e co

ntro

l, di

scon

nect

bot

hco

nnec

tors

from

the

blow

er m

otor

PL1

3an

d P

L14.

Doe

s th

e bl

ower

whe

el tu

rnfr

eely

?

Rep

lace

the

blow

er c

ontr

ol m

odul

e at

tach

edto

the

blow

er m

otor

. Fo

llow

the

inst

ruct

ions

with

the

blow

er c

ontr

ol m

odul

e to

mak

e su

reth

e en

tire

blow

er m

otor

doe

s no

t nee

d to

be

repl

aced

.

You

have

an

open

wire

or

bad

term

inal

on

the

BLU

E w

ire b

etw

een

the

furn

ace

cont

rol a

ndth

e bl

ower

mot

or.

Rep

lace

the

furn

ace

cont

rol.

Con

nect

a D

C v

oltm

eter

acr

oss

PL3

-4 B

LUE

(+)

and

PL3

-2 G

RE

EN

(-)

. D

oes

the

volta

geflu

ctua

te a

s de

scrib

ed tw

o st

eps

back

?

Doe

s th

e vo

ltage

fluc

tuat

e as

des

crib

ed in

the

prev

ious

ste

p?

Rep

lace

the

blow

er c

ontr

ol m

odul

e at

tach

edto

the

blow

er m

otor

. Fo

llow

the

inst

ruct

ions

with

the

blow

er c

ontr

ol m

odul

e to

mak

e su

reth

e en

tire

blow

er m

otor

doe

s no

t nee

d to

be

repl

aced

.

Turn

pow

er b

ack

on.

Is th

ere

115V

AC

at

PL1

4-5

and

PL1

4-4?

Is th

ere

12-V

DC

at P

L13-

7 R

ED

(+) a

nd P

L13-

1 G

RE

EN

(-)

?

Is th

ere

12-V

DC

at P

L3-1

RE

D (

+) a

nd P

L3-

2 G

RE

EN

(-)

?

Rep

lace

the

furn

ace

cont

rol.

Is th

ere

5-V

DC

at P

L13-

16 Y

ELL

OW

(+) a

ndP

L13-

1 G

RE

EN

(-)

?

The

vol

tage

just

mea

sure

d sh

ould

be

very

stab

le a

nd s

houl

d no

t flu

ctua

te m

ore

than

.02-

VD

C.

If th

e vo

ltage

fluc

tuat

es m

ore

than

this

get

a d

iffer

ent v

oltm

eter

bef

ore

proc

eedi

ng.

Turn

pow

er o

ff, r

econ

nect

PL1

3 an

d P

L14

toth

e bl

ower

mot

or, t

hen

turn

pow

er b

ack

on.

Con

nect

a D

C v

oltm

eter

acr

oss

PL3

-3Y

ELL

OW

(+)

and

PL3

-2 G

RE

EN

(-)

. D

oes

the

volta

ge fl

uctu

ate

mor

e th

an it

did

in th

epr

evio

us s

tep?

Turn

pow

er o

ff, d

isco

nnec

t PL1

3 an

d P

L14

from

the

blow

er m

otor

, the

n tu

rn p

ower

bac

kon

. C

onne

ct a

DC

vol

tmet

er a

cros

s P

L13-

16 B

LUE

(+)

and

PL1

3-1

GR

EE

N (

-).

The

volta

ge s

houl

d be

nea

r 0-

VD

C b

ut it

will

fluct

uate

brie

fly s

ever

al ti

mes

a s

econ

d. I

fyo

u ha

ve a

n an

alog

vol

tmet

er th

e ne

edle

will

brie

fly g

o hi

gh s

ever

al ti

mes

a s

econ

d. I

f you

have

a d

igita

l vol

tmet

er w

ith a

bar

gra

ph it

will

sho

w a

larg

e ch

ange

in m

agni

tude

on

the

bar

grap

h se

vera

l tim

es a

sec

ond.

If y

ouha

ve a

sta

ndar

d di

gita

l vol

tmet

er it

will

sho

wa

brie

f flu

ctua

tion

in v

olta

ge a

nd th

em

agni

tude

may

var

y de

pend

ing

on th

evo

ltmet

er u

sed.

You

have

an

open

wire

or

bad

term

inal

on

eith

er th

e B

LAC

K o

r WH

ITE

pow

er le

ads

betw

een

the

furn

ace

cont

rol a

nd th

e bl

ower

mot

or.

If yo

u ha

ve a

pow

er c

hoke

dis

conn

ect

it an

d ch

eck

cont

inui

ty.

You

have

an

open

wire

or

bad

term

inal

on

eith

er th

e R

ED

or

GR

EE

N w

ire b

etw

een

the

furn

ace

cont

rol a

nd th

e bl

ower

mot

or.

Is th

ere

5-V

DC

at P

L3-3

YE

LLO

W (

+) a

ndP

L3-2

GR

EE

N (

-)?

You

have

an

open

wire

or b

ad te

rmin

al o

n th

eY

ELL

OW

wire

bet

wee

n th

e fu

rnac

e co

ntro

lan

d th

e bl

ower

mot

or.

YE

S

NO

NO

NO

YE

S

YE

S

YE

S

YE

S

YE

S

YE

S

NO

NO

NO

NO

NO

YE

S

YE

S

NO

42IN

DU

CE

R M

OTO

R F

AU

LT-

Indi

cate

s th

ein

duce

r m

otor

has

not

sta

rted

with

in 2

0se

cond

s af

ter

a ca

ll fo

r he

at, t

he in

duce

rm

otor

RP

M is

out

side

its

valid

ran

ge o

fop

erat

ion,

or t

he in

duce

r RP

M s

igna

l was

lost

for

5 se

cond

s du

ring

oper

atio

n.C

heck

for:

-P

rope

r ve

nt s

izin

g.-

Faile

d in

duce

r m

otor

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A06461

58UVB

19

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase yourknowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating SequenceA large selection of product, theory, and skills programs is available, using popularvideo-based formats and materials. All include video and/or slides, plus companionbook.

Classroom Service Training plus "hands-on" the products in our labs can meanincreased confidence that really pays dividends in faster troubleshooting, fewercallbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service TrainingA94328

Copyright 2006 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No:58UVB--1SM

Replaces:New

Printed in U.S.A. Edition Date: 08/06

58UVB

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